Method of producing metallic dies



K. w. coUsE METHOD OF PRODUCING METALLIC DIES Filed Maron 17, 1951 f): Jg:

June 6, 1933.

w. Cou se w11.. U...A

.v Patentedv June 6,1933

maar w. coUsE, .or Taos, NEW Mnxrco METHOD 0F PRODUCING' METALLIC DIES .Application med March 17, 1931. Seria1 No. 523,238.

This invention relaties to a method of producing metal1ic-dies, and an object is to provide an improved method vwhereby metalllc diesv for use in various relations, as for 11istance the production of die castings and vthe like, maybe readily produced at small cost. A A further object is to provide a method whereby such dies may be produced having great accuracy of form and 'of hlgh quality and durabilit Other objects and aims of the mventlon, more or less specific than those referred to above, will lbe in p art obvious and 1 n part 5 pointed out in the cqurs'e of the following dei scription of theelements, combinations, arrangments of parts, steps of procedure and applications of rincipls constitutmg the invention; and t e scope of protectlon contemplated will be indicated in the appended claims.

'the parts of Fig."7 as they appear in position within a suitable mold.

Fig. 9 is a View similar to Fig. 8 but the removable material being now removed.

Fig. l0 is a view similar to Fig. 9 but'the 55 removable material of Fig. 8 being replaced by metal, and' Fig. 11 is a perspective view illustrating the mating pair of metallic die blocks as they vappear when completed.

The various steps of procedure illustrated may be described as follows:

In Fig. 1 an article consisting of two half models, or half masters, as L and G are lation at opposite sides of a carrier plate as H. These elements, L, G and -H may be of any appropriate material such as wood, composition, metal, or otherwise, and it will be understood that the half masters L and G '70 shown,'being arranged' in proper mating re- 65- l if brought together without the presence of In the accompanying drawing which is to be taken as a part of this speclicatlon, and in which I have shown merely a preferred form of device by which to perform Athe present method. v v

Fi 1 is an elevational viewillustratlng Y a pair of half masters mounted upon a carrying plate. Fig.I 2 is a similar view illustrating the partsof Fig. 1 as having a surface treatment thereon.

-' Fig. 3 is 'a similar view but showing the parts of Fig. 1 as beingl further coated with a coatingof metal. 1

Fig. 4 is a similar view illustrating an additional coating of metal upon 1the parts shown in Fig. 1.

Fig. 5 is a sectional view illustrating the metallic half shells.

Fig. 6 is a similar sectional view showing carrying plate.

Fig. 7 is a similar sectional view showing the parts of Fig.. 6 as being built up with a suitable removable material.

Fig. 8 is a similar sectionalview 4showing several coatings now constituting a pair of the carrier plate H, are of the precise' form Vfor. which the finished dies, or dieblocks, is

desired.i Each half master constitutes a pattern for the moulding cavity or -impression of one die block. They may for instance be l a wood or metallic model of the precise article which is to, be reproduced b the die.

-The-carrier plate I-I may be o any appropriate thickness*A but its height and width 8 correspond preferably with the height and width ofthe completed die blocks to be pro-A duced. v

After applying a light coating ofsgrease vor other appropriate treatment, as indicated 851 by the dotted lines 1 in Fig. 2, to the opposite side surfacesof the lparts illustrated in Fig. 1, thensaid surfaces are flashed over with a very light coating'of copper plating, -90

as indicated at 2 in Fig. 3, and then said surfaces are covered with a layer of nickel as indicated at 3 in Fig. 4.

The layers 1, 2 and 3 may be applied-in any appropriate manner, but the layers 2 and 3 at least are preferably applied by elec-'1 95 tro-depositionor metalspraymg or in like manner. 1 It may be lhere noted that the layer of grease 1 is merely tol prevent adhesion of the 100 copper 2A to the master, and that the copper -6o sions, that is the walls of the cavities 5 5 is merely an expedient to facilitate the appslication of the nickel' 3 upon the master.

oth the grease and the copper are negligible elements in the nal result. The grease disappears completely, and the copper is so thin as to be of no consequence. The coating 3 of nickel however is of such thickness as to constitute a vpair of substantial half shells as 4 4 which may be readily lifted away from opposite sides of the masters, and according to this invention, said shell parts, as indicated in Fig. 5, are to be separated from the masters, and from the plate H. The cavities as' 5 5 of course have the identical shape of the exterior surface of the parts L and Gr.

l The walls of the cavities are of nickel, the

copper 2 being, as above stated, of such great i thinness as to be of no consequence.

These two shell parts 4 4 are now filled with a suitable refractory material as 6 6, such as fireclay, or carbon paste, or the like, and are now dried and mounted back to back upon a carbon or other suitable plate 7 which corresponds with or replaces the carrier plate H, as illustrated in Fig. 6. n

After the shell parts have been filled and mounted upon the plate 7 as in Fig. 6 then they are built up'with wax or the like as at 8 8 to represent the desired die blocks as indicated in Fig. 7.

After the wax has been applied as in Fig. 7 then the whole is used as a'pattern about which a mould 9 is rammed up as indicated in Fig. 8.

After the mould has been completed as in Fig. 8 then heat is applied and the wax thereby melted and drawn off so that the .two

' shells 4 4 with their filling 6 and the intervening carbon plate 7 is left standing within' the mould with open spaces 10-10 at opposite sides previously occupied by the wax, as indicated in Fig. :9.

After the wax has been withdrawn as in Fig. 9 then the mould is lled in the usual manner with a suitable molten metal 11 such as iron, steel, bronze, thermit nickel steel or otherwise, the thermit nickel steel being preferable on account of its high melting point, ease of obtaining the desired composition and the purity of the resulting metal, as indicated in Fig. 10. l

, It is a feature of this invention that the metal 11 when poured into the mould shall alloy with the metal comprising the shell parts 4 4 but'without breaking down said shell parts. Where the shell parts 4 -4 are of nickel, the thermit nickel steel, ,alloying therewith vbut not breaking down said shell parts, will produce a pair of nickel steel die blocks wherein the surfaces of the impresabove referred to, are rich in nickel. 4

After the metal 11 has been allpwed to cool and has been removed from the mould 9, and the gates cut-olf, the llers 6 6 and -cisely the same contour as the masters L and G and any number of die blocks maybe produced from a single pair of masters and all will be of the same uniform accuracy in every respect. The walls of the' impression cavities may be of any desired metal, and the bodies of the die blocks may likewise be made of any desired material, all to the end that the finished die blocks maybe of desired efficiency for their intended purpose at a minimum of production cost. If the die blocks are to be used for the casting of material having a high melting point then the materials used in the die block formation should of course have a high melting point,

whereas if the" dies are to be used for the cast-- be correspondingly cheaper and of lower' melting po1nt.

It may be stated that if desired the steps indicated in Figs. l to 4, and by which the shell parts 4 4 of Fig. 5 are produced, may in some instances be omitted and that said shell parts 4 4 may be produced by any other preferred means such for instance as by being stam ed up or pressed -into form from-a piece o appropriate sheet metal.

Also it may be noted that in some instances if preferred the refractory materials 6 6 and 7, instead of vbeing used as a filler for the completed shell parts 4.-4, may themselves be used as a master,n u n which said shell parts may be'formed directly.

Having thus described my invention, what I claimv as new and desire to secure by Letters Patent is 1. The herein described method of productory material, mounting said filled half shellsv in mating relation upon the opposite side surfaces of a suitable carrying plate, building up with removable material t e outer` surfacesico of said-half shells to the'size vdesired for the f completed die blocks, providing a mold about said built up half shells and carrying plate, removing said removable` material so as to leave said half shells in supportedrelation upon the carrying plate within the mold, lling the mold with molten metal to replace said removed material and to alloy with'the metal 'of the half shells without breaking down said half shells, and then allowing the whole to cool and removing theu completed die blocks from the mold and from said carryin late and refractory llug material.

2. he herein described method of produc- .5 ing a`matin pair of metallic die blocks gwhich meth consists in providing a pair o half masters, mounting said half masters in mating relation upon the opposite side surfaces of a suitablev supporting plate marginal portions of which project beyond said half masters, forming metallic half shells upon' saidplate andA said half masters so that said half shells it accui'ately to said plate and, half masters and hence have interior contours corres onding with the interior contours desired or the impression cavities of the die blocks, removing said half shells from said plate and half masters, filling the cavities o'f said half shells with refractory material, mounting said filled half shells in mati relation upon the op osite side surfaces. o a suitable carrying p ate, building up with removable material the outer surfaces of said half. shells to the size desired for the completed die blocks, providing a mold about said built up half shells and carrying plate, removi said removable material while said half shlis continue undisturbed in @up orted relation upon thecarrying plate within 3p the mold, filling the mold with molten metal to replace said removed material and to alloy with the metal of' the half shells without breaking down-said half shells, and then a1- lowin the whole to cool and removing the comp eted die .blocks from the `mold and from said carrying plate and refractory lilling material. Y, In testimony whereof I affix my si ature.

v `KIBBEY W. CO SE. 

